Run flat tire support and colorant therefor

ABSTRACT

The present invention provides a unitary run flat tire (RFT) reinforcement that is formed into a relatively rigid shape. The reinforcement is insertable into a mold for an RFT support and can maintain the needed structural rigidity for such insertion. Further, the invention provides an RFT support that is molded and includes the RFT reinforcement. The invention also provides a wheel assembly including a tire, a rim, and an RFT support between the rim and the tire, where the support includes the RFT reinforcement. The RFT support can have a colored indicator formed or subsequently applied thereto to indicate one or more attributes of the support.

[0001] This application claims the benefit of U.S. ProvisionalApplication Ser. No. 60/231,658, filed Sep. 11, 2000; Ser. No.60/289,958, filed May 10, 2001; and Ser. No. 60/300,887, filed Jun. 25,2001, all incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The field of invention relates to pneumatic tires. The inventionparticularly relates to run flat tire supports for pneumatic tires.

BACKGROUND OF THE INVENTION

[0003] In past years, the automotive industry has provided spare tiresfor replacement of punctured or blown out tires while traveling.However, efforts have been made to eliminate the need for the spare tireby providing improved designs for tires. Specifically, efforts have beenmade to provide a stable and economical tire that can run with little orno pressure when, for example, the tire is flat. The term for theefforts has become known as “run flat tire” (RFT) technology. The RFTconcept allows an operator to continue driving or rolling for anextended period of time without stopping to replace the tire or seekingemergency assistance. A tire can be repaired at a later, more convenienttime.

[0004] One embodiment of an RFT wheel assembly includes a rim, a tiremounted on the rim, and a support sandwiched between an inner surface ofthe tire and an outer peripheral surface of a rim. The support allowsthe tire to deflect a limited amount so that the tire does not separatefrom the rim along each edge of the tire. A synthetic material, such asa polymer, is typically used for the support.

[0005] The process of producing an RFT support typically involves sometype of molding. A mold for the support can include a narrow channel ofabout three millimeters (mm) in width that is formed about an inner orouter periphery of the mold. The polymer support can be reinforced tohelp maintain its structural integrity during adverse conditions byproviding a reinforcement in the molding process. The reinforcement isplaced in the channel prior to molding and the polymer typically flowstherethrough to encapsulate the reinforcement into the molded RFTsupport.

[0006] RFT supports can vary by manufacturer, size, style, and otherattributes. Shipping, installation, repair, and other post-manufacturinguses need clear identification of the various RFT supports. For example,different RFT supports can be unintentionally and perhaps dangerouslyinstalled on improper rims and/or tire combinations.

[0007] Therefore, there remains a need for an RFT support that includessome visual indicator of one or more of the attributes of the RFTsupport to avoid confusion with other RFT supports.

SUMMARY OF THE INVENTION

[0008] The present invention provides a unitary run flat tire (RFT)support that includes a visual colored indicator. The colored indicatorcan be formed reinforcement that is formed into a relatively rigidshape. Generally, the unitary RFT support reinforcement can be formedfrom multiple layers that are coupled together, such as with anadhesive, to form one effective layer. The one effective layer caninclude layers of cloth or, advantageously, layers of filaments woundinto a reinforcement. The reinforcement is insertable into a mold for anRFT support and can maintain the needed structural rigidity for suchinsertion.

[0009] Further, the invention provides an RFT support that is molded andincludes the RFT reinforcement. The invention also provides a wheelassembly including a tire, a rim, and an RFT support between the rim andthe tire, where the support includes the RFT reinforcement. The RFTsupport can have a colored indicator formed or subsequently appliedthereto to indicate one or more attributes of the support.

[0010] The present invention provides a run flat tire (RFT) support,comprising a molded portion having an outer circumference and an innercircumference and adapted to mount to a wheel rim to support a deflatedtire when the tire is rolling on a surface, the molded portion furthercomprising a colored indicator that indicates at least one attribute ofthe RFT support; and at least one RFT reinforcement molded into themolded portion.

[0011] An RFT support is provided, comprising a molded portion having anouter circumference and an inner circumference and adapted to mount to awheel rim to support a deflated tire when the tire is rolling on asurface, the molded portion having a colored indicator that indicates atleast one attribute of the RFT support.

[0012] A method of manufacturing an RFT support is also provided,comprising flowing a moldable material into an RFT support mold to formthe RFT support; and visually identifying at least one attribute of theRFT support by adding a preselected colorant to at least a portion ofthe RFT support.

[0013] A method of installing an RFT support on a wheel rim is alsoprovided, comprising selecting a wheel rim; and selecting an RFT supportsuitable to the wheel rim based on a colored indicator formed on the RFTsupport, the colored indicator indicating at least one attribute of theRFT support.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014]FIG. 1 is a schematic partial cross sectional view of a wheelassembly.

[0015]FIG. 2 is a perspective schematic view of an RFT support.

[0016]FIG. 3 is a schematic side view of another embodiment of the RFTsupport.

[0017]FIG. 4 is a schematic view of an RFT reinforcement.

[0018]FIG. 5A is a schematic perspective view of another embodiment ofthe RFT support.

[0019]FIG. 5B is a partial schematic cross-sectional view of an openingformed in the embodiment shown in FIG. 5A.

[0020]FIG. 6 is a schematic view of one system for producing a filamentwound RFT reinforcement.

[0021]FIG. 6a is a detailed schematic of one embodiment of transversemembers and circumferential members and associated winding.

[0022]FIG. 7 is a schematic view of another embodiment of a system forproducing an RFT reinforcement by wrapping reinforcement material arounda mandrel.

[0023]FIG. 8 is a schematic view of another embodiment of the system formolding an RFT reinforcement.

[0024]FIG. 9 is a schematic view of another embodiment of the system forproducing a reinforcement having longitudinal members.

[0025]FIG. 10 is a schematic view of another embodiment of a system forproducing an RFT reinforcement using a tangential molding process.

[0026]FIG. 11 is a schematic perspective view of a RFT support having acolored indicator.

[0027]FIGS. 12a-12 f is a schematic perspective view of exemplarycolored indicators on a RFT support.

DETAILED DESCRIPTION OF THE INVENTION

[0028] The present invention generally includes a colored run flat tire(RFT) support including the RFT reinforcement, and a wheel assemblyincluding the RFT support, tire, and rim. Further, the inventionincludes methods of manufacturing the RFT support and reinforcement.

[0029]FIG. 1 is a schematic partial cross sectional view of a wheelassembly. A wheel assembly 10 includes a rim 12, a tire 14 mounted onthe rim, and an RFT support 16 mounted between an inner peripheralsurface of the tire and an outer peripheral surface of the rim. In someembodiments, the rim 12 can include a center support 24 which allowsattachment of the wheel assembly 10 to a vehicle (not shown). The centersupport 24 can generally can be a web, spokes, or other attachmentelement, and can include a separate multi-piece element, as is known inthe commercial trucking industry for wheel assemblies. The rim 12 alsoincludes a first rim flange 26 and a second rim flange 28. The outerdiameter of the RFT support 16 is generally the same or greater than theinner diameter of the tire 14 at the beads 30 and 32. The RFT support 16is generally compressed circumferentially in at least one direction toan elliptical shape so that the RFT support can be inserted within thetire 14 generally prior to insertion of the RFT support onto the rim 12.Thus, the support 16 should be relatively rigid to support a load of thetire in an underinflated condition, but is also sufficiently flexible toallow changing the shape for installation. The materials for the RFTsupport are discussed in reference to FIG. 2.

[0030] The RFT support 16 includes an outer hoop 18, and inner hoop 20,and a center web 19 disposed therebetween. Further, the RFT support 16includes at least one RFT reinforcement 22 molded therein. The RFTsupport can have a colored indicator on one or more of the RFT supportsurfaces as described more fully in reference to FIGS. 11-12.

[0031] The RFT Support

[0032]FIG. 2 is a perspective schematic view of an RFT support 16, shownin FIG. 1. The RFT support 16 includes in one embodiment an outer hoop18 generally having a tire support surface 15 for the tire 14 that isshown in FIG. 1, an inner hoop 20 generally having a rim support surface21 for the rim 12 that is also shown in FIG. 1, and a center web 19disposed therebetween.

[0033] At least one RFT reinforcement 22 is molded into the RFT support.Generally, the RFT reinforcement is molded into the inner hoop 20,although the reinforcement could be molded in other areas of thesupport, including the outer hoop 18 and the center web 19. Further,multiple RFT reinforcements can be molded at more than one position inthe RFT support. For example, multiple RFT reinforcements could bemolded at either different diametrical spacings or different lateralspacings, such as side-by-side, in the RFT support.

[0034] Generally, the RFT reinforcement is formed into a unitary member,in that, the reinforcement is a substantially continuous member, such asa cylinder, having one effective layer prior to inserting thereinforcement in a mold for molding. If the RFT reinforcement is formedfrom a plurality of elements or layers, then generally the elements orlayers are coupled together through mechanical attachment, chemicalattachment, such as with coatings that would include binders, adhesives,and other substances that cause adherence between at least two elementsor layers, or other methods that would join such portions together toform one effective layer. The reinforcement does not need couplingaround the entire periphery to be considered having “one effectivelayer” for the purposes of this invention. Rather, such term is definedfunctionally, in that the reinforcement is coupled togethersufficiently, so that it can be held together without substantialdelamination, as described herein. Advantageously, the reinforcement canbe coupled around at least the majority of its periphery. Generally, thecoupling of the multiple layers together should be sufficient to remainintact during customary handling procedures of a manufacturing process,so that the layers do not delaminate. Delamination can cause delays in amanufacturing process during insertion of the reinforced member into theRFT support mold.

[0035] The loft of the material used in the RFT reinforcement can bereduced in some embodiments, especially when a coating is used to reducethe thickness of the material and/or to retain fibers to adjacentfibers. The thinner material can assist in placement in a mold. Thereinforcement 22 assists in resisting crack propagation in the RFTsupport and otherwise contributes to the structural integrity of thesupport 16, particularly when the support 16 is mounted on the rim 12,shown in FIG. 1, and placed in use.

[0036] The center web 19 can include openings 40 to achieve weightreduction and material savings. The openings 40 can be any geometricshape and generally are round, elliptical, square, triangular,rectangular, parallelogram, rhombus, or diamond shaped. The center web19 can be made of a flexible material to allow flexing of the supportfor installation in the wheel assembly 10, described in reference toFIG. 1.

[0037] The support 16 can be formed through molding and one embodimentis formed through reaction injection molding (RIM), a technique known tothose with ordinary skill in the art. For the purposes of thisdisclosure, RIM can also include, without limitation, variations such asstructural reaction injection molding (SRIM) and reinforced reactioninjection molding (RRIM). Other methods can include resin transfermolding (RTM), thermoplastic injection molding, blow molding, rotationalmolding, foam molding, bead foam molding, compression molding, profileextrusion, and spin casting. These various techniques are known in theindustry for producing molded parts. The material for the RFT supportcan be any moldable material. Suitable materials for use in preparingthese RFT supports include, for example, the classes of thermoplasticelastomers commercially available according to the “Handbook ofThermoplastic Elastomers,” 2nd Edition, edited by B. M. Walker andCharles P. Rader, Van Nostrand Reinhold, New York, 1988. These are:styrenic block copolymers; rubber-polyolefin blends; elastomeric alloys;thermoplastic polyurethanes; thermoplastic copolyesters; andthermoplastic polyamides. Under the category of elastomeric alloys,there are thermoplastic vulcanizates (TPVs) and melt processable rubbers(MPRs). Other useful materials can include polyvinyl chloride;polyethylene copolymers (including ethylene/styrene copolymers viaconstrained geometry catalysis); hydrogenated styrene block copolymers;polylactic acid polymers; and ethylene/carbon monoxide copolymers.

[0038] There are also a number of thermosetting or vulcanizableelastomers commercially available according to “Rubber Technology;” 3rdEdition, edited by M. Morton, Kluwer Academic Publishers, Boston, 1999which can be used to prepare the RFT supports. These elastomers includenatural rubber (cis-1,4-polyisoprene); styrene-butadiene rubbers;polybutadiene rubbers; polyisoprene rubbers; ethylene-propylene rubbers,polychloroprene polymers; chlorinated polyethylene; chlorosulfonatedpolyethylene; silicone rubbers; flurocarbon elastomers; polyurethaneelastomers; polysulfide elastomers; hydrogenated nitrile rubbers;propylene oxide polymers (vulcanizable copolymers of PO and allylglycidyl ether); epichlorohydrin polymers; and ethylene acrylicelastomers (ethylene/methyl acrylate/carboxylic acid containing monomerterpolymers). Another material is polycoprolactam/polyether copolymers,such as NYRIM®. Curing, as appropriate, can be accomplished throughself-cure, catalytically induced cure, thermal cure, photo sensitivecure, free radically initiated cure, actinic cure, such as X-ray cure,electron beam cure, microwave cure, and other cures known to those ofordinary skill in the art.

[0039] Further, exemplary polyurethanes suitable for the RFT support caninclude at least one polyol, at least one chain extender, and at leastone isocyanate. Such polyurethanes include those materials cited andprepared in accordance the disclosure in PCT application WO 01/42000, byThe Dow Chemical Company of Midland, Mich., USA, the assignee of thepresent invention.

[0040] PCT publication WO 01/42000 describes polyurethane-polymercompositions that are useful for making a lightweight tire support.Example 1 of this PCT publication describes one composition that can beparticularly useful, although other materials can be used. In Example 1,a polyurethane-polymer composition was prepared by admixing apolyol-side stream and an isocyanate-side stream using reactioninjection molding.

[0041] The polyol-side stream included a polyol formulation. The polyolformulation included a polyol in an amount of 54.81 weight percent, achain extender in an amount of 44.84 weight percent, a surfactant in anamount of 0.25 weight percent, and a catalyst in an amount of 0.1 weightpercent.

[0042] For the polyol formulation, the polyol was an ethylene-oxidecapped 5,000 molecular-weight triol having a maximum unsaturation of0.035 milliequivalents per gram of the total composition (available fromThe Dow Chemical Company, Freeport, Tex.). The chain extender wasdiethyl toluene diamine (a mixture of 3,5-diethyl-2,4- and 2,6′-toluenediamines) (available from The Dow Chemical Company, Freeport, Tex.). Thesurfactant was a silicone surfactant (L-1000; available from OSISpecialties/Witco Corp., Chicago, Ill.). The catalyst included a 50:50combination of triethylene diamine (Dabco 3LV) (available from AirProducts and Chemicals, Inc., Allentown, Pa.) and dibutyl tin dilaurate(Fomrez UL28) (available from Witco Chemical Co., Chicago, Ill.)

[0043] The isocyanate-side stream included a prepolymer formulation. Theprepolymer formulation included a first isocyanate in an amount of 31.83weight percent, a polyol in an amount of 63.17 weight percent, and asecond isocyanate in an amount of 5.0 weight percent.

[0044] For the prepolymer formulation, the first isocyanate was 98percent pure p,p′-MDI (Isonate 125M) (available from The Dow ChemicalCompany, Freeport, Tex.). The polyol was an ethylene-oxide capped (15percent) 6,000 molecular-weight triol with a maximum unsaturation of0.02 milliequivalent per gram of total composition (available fromAsahi). And the second isocyanate was 50 percent p,p′-MDI and 50 percento,p-MDI (Isonate 50 OP) (available from The Dow Chemical Company,Freeport, Tex.).

[0045] The isocyanate-side stream and the polyol-side stream werecombined in a weight-ratio blend of 2:15:1 (isocyanate to polyol) usingstandard reaction-injection-molding processing conditions.

[0046] One skilled in the art will recognize that the formulation inthis example can vary for the purposes of the present invention. Forexample, testing conditions, tolerances in formulation of raw materials,and variances with processing can alter the composition withinacceptable ranges. Further, the formulation can be modified to alterproperties of the tire support, such as but not limited to, altering theratio of chain extender and polyol, eliminating a second isocyanate, andusing polyols that are not ethylene-oxide capped. Still further, theranges given in the PCT publication WO 01/42000 can also produce othersuitable formulations.

[0047]FIG. 3 is a schematic side view of another embodiment of the RFTsupport. The RFT support 16 in the embodiment shown in FIG. 3 includes aset of components that can be molded in separate operations. The RFTsupport 16 includes an outer hoop 18, a center web 19, and an inner hoop20, which in at least one embodiment includes an RFT reinforcement 22.In some embodiments, the hoops and/or web can be formed from one or morethermoplastic foams, such as elastomer bead foams. Optionally, the hoopsand/or web can be unfoamed. For example, the inner hoop 20 can be formedof a dynamic thermoplastic foam.

[0048] The density can be controlled to provide a relatively rigid innerhoop. The RFT reinforcement 22 can be formed of a fibrous or othersuitable material and, in at least one embodiment, is coupled to theinner hoop by being affixed or molded therein. The center web 19 can beformed of a lower density dynamic thermoplastic foam. The center web 19can optionally contain load bearing optimized openings (not shown) forweight reduction. The outer hoop 18 can be a higher density dynamicthermoplastic foam. The combination can provide sufficient strength tothe inner surfaces, such as the inner hoop 20, and still be sufficientto allow the shape to change as needed for installation of the RFTsupport into the tire 14 and onto the rim 12, as shown in FIG. 1.

[0049] The hoops and/or web can be molded using a conventional molding,such as foam or bead foam molding techniques known to those withordinary skill in the art. For example, a portion of the inner hoop 20can be formed and an RFT reinforcement 22 placed around the portion toform the inner hoop. The inner hoop 20 can optionally be prepared usinga profile extrusion system. The inner hoop 20 could be reinforced by theRFT reinforcement 22 molded therein. The center web 19 can be moldedaround the inner hoop 20 and the RFT reinforcement 22. The outer hoop 18can be molded around the center web 19.

[0050] One skilled in the art having read this specification wouldunderstand that the RFT reinforcement 22 can be disposed in otherpositions in the RFT support 16. For example, the RFT reinforcement canbe disposed or otherwise formed in or adjacent to the outer hoop 18 orthe center web 19.

[0051] RFT Reinforcement

[0052]FIG. 4 is a schematic view of an exemplary rigid, unitary RFTreinforcement. The RFT reinforcement 22 generally includes at least onetransverse member 42. In the embodiment shown, a second transversemember 42 a intercepts the transverse member 42. Further, thereinforcement 22 can include at least one substantially circumferentialmember 44. In at least one embodiment, the transverse members 42, 42 acan be wound symmetrically, that is, at similar angles with respect to acenter axis 23. Transverse angles α₁, α₂ can be used to describe theangle of the transverse members 42, 42 a, respectively, relative to thecenter axis 23. In one embodiment, the transverse angles can be morethan about 0 degrees to less than about 90 degrees, and advantageouslyabout 70 degrees to about 80 degrees, such as about 78 degrees.Alternatively, the angles can be different from each other. Oneexemplary spacing 43 between adjacent transverse members can be about 20mm to about 30 mm, such as about 24 mm. The transverse members can be avariety of widths and in at least one embodiment can be between about 2mm to about 5 mm, such as about 3 mm.

[0053] Similarly, in at least one embodiment, the circumferentialmembers 44 can be a width generally of about 2 mm to about 10 mm, suchas between about 5 mm to about 8 mm. The circumferential members can beequally or non-equally spaced across a width of the RFT reinforcement ofabout 70 mm to about 120 mm, such as about 90 mm. A circumferentialangle β can be used to describe the angle of the circumferentialmember(s) and generally is a large angle, that is, almost perpendicularto the axis 23, although any angle between about 0 degrees and about 90degrees can be used. In at least one embodiment, the angle β can bebetween about 80 degrees to about 90 degrees.

[0054] It would be understood to one with ordinary skill in the art thatthe above dimensions are exemplary and the angles, uniform andnonuniform spacings, sizes, number of members and other dimensions canall vary depending on various design parameters, such as materials,desired rigidity, ease of assembly, costs, and strength. Further, thetransverse members and circumferential members can be formed fordifferent filaments or from a common filament, as described belowregarding FIG. 6.

[0055] The RFT reinforcement of the present invention advantageously hasa higher rigidity than found in prior efforts. The higher rigidityallows the reinforcement to be manually or automatically handled and tobe placed relatively quickly in position in an RFT support mold. Thespeed and efficiency improves the productivity of an RFT support whichshould, in turn, allow for the economic production of the massquantities of supports required for the transportation market.

[0056] A prior art RFT reinforcement comprising multiple layers of ascrim cloth took about 45 seconds to place in an RFT support mold in onecomparative test. In contrast, some tests using at least one embodimentof the RFT reinforcement disclosed herein took about 10-15 seconds orless to place in the mold, that is, less than one-third of the timeusing the prior art. Even more advantageously, the tests showed that itwas possible to reduce the time to about 2-5 seconds or less andgenerally about 3 seconds or less, that is, about an order of magnitudedifference in time from the prior art.

[0057] Initial tests were conducted in manually placing the RFTreinforcement described herein in the mold. Automatic placement can alsobenefit using the RFT reinforcement described herein, for example andwithout limitation, through robotic placement or other automatic orsemi-automatic placement systems.

[0058] The RFT reinforcement can also contain openings 46 formedtherethrough. The openings allow liquid reactants to penetrate thereinforcement during the molding process of the RFT support, so that thereinforcement becomes an integral part of the RFT support when theliquid reactants solidify. Preferably, the reinforcement issubstantially encapsulated by the polymer.

[0059] The RFT reinforcement can be made from a variety of moldable andmetallic materials. For example, the transverse members and/orcircumferential members can be made of fiberglass, carbon/graphitefibers, aramid fibers, polyester fibers, metal fibers and othermaterials. The types of fibers can be combined into composites toinclude combinations of glass, carbon/graphite, aramid, polyester, metaland other materials. The material can include metallic cloth materials,such as wire mesh, or solid rings. The fibers can additionally include abinder, sizing, dressing, or other coating to facilitate processing,binding or heat sealing of the fibers.

[0060] The individual fibers can be formed into filaments or tape. Thefibers can be cut into discrete layers to produce cut fibers and can beincluded in a moldable material. In this disclosure, the term “filament”is used broadly and includes ribbons, fibers, tapes, yam, tow, roving,and other individual, or groups of, materials to be wound about themandrel. Unless explicitly stated herein, the term “mandrel” includes amember around which the filaments or other material are wound or formed.The mandrel can be reused for subsequent winding or forming, or can beintegrated into the RFT reinforcement and/or RFT support in theprocessing of the same, for example, by cutting the member as a portionof the RFT support or RFT reinforcement. A collapsible mandrel can beused to advantage to facilitate the removal of the RFT reinforcement.

[0061] Additional materials for the reinforcement can include thinstrands of wire woven into the material. Further, the reinforcement canbe made from sheets, and in some embodiments laminated sheets. The RFTreinforcement can also be made of reinforced thermoplastic containingfibers. For example, the fiber composition of the thermoplastic canrange from about 20% to about 99%, although other percentages arepossible. Generally, the RFT reinforcement comprises a weight per squaremeter of about 50 grams to about 1000 grams per square meter.

[0062] An important aspect is that the reinforcement be sufficientlyrigid to allow relatively quick and easy insertion into the mold andstill be sufficiently flexible to allow compression of the RFT supportfor installation of the RFT support into the wheel assembly, shown inFIG. 1. Further, the reinforcement can be sufficiently rigid to helpprovide structural resistance to the otherwise outward expansion of themolded support during rotation and the accompanying outward centrifugalforces, such that the support substantially maintains its structuralintegrity during its intended use. For purposes herein, such stiffnesswill be referred to as “hoop stiffness,” that is, the ability to resistan outward expansion due to rotating radial forces.

[0063] To increase hoop stiffness, the fibers can have a coating appliedthrough spraying, dipping, encapsulating, extruding, impregnating,combining with films, or other methods known to those in the art thatare available before or after the fibers are formed into an appropriateshape for the RFT reinforcement to produce a self-supporting structurethat is capable of not collapsing when the structure is without externalsupports. Further, the reinforcement material could be dipped in acoagulation dip coating prior to forming around a mandrel and arelatively rigid polymer could be applied to act as an aqueousdispersant to provide suitable the self-supporting structure. Thereinforcement preferably advantageously has a balanced weightdistribution around the reinforcement periphery to assist thecentrifugal balance of the final RFT support during driving conditions.

[0064] The RFT reinforcement can be made in individual units or can bemade as a tubular member and one or more reinforcement units cut fromthe tubular member. The RFT reinforcement can be filament wound about amandrel. Alternatively, the RFT reinforcement can be made from preparedcloth or sheets that are rolled into a desired shape and the ends orother portions of the material coupled to each other. The term“coupled,” “coupling,” and like terms as used herein includes adhering,bonding, binding, curing, fastening, attaching, and other forms ofsecuring one piece to another piece.

[0065]FIG. 5A is a schematic prospective view of another embodiment ofthe RFT reinforcement 22. In this embodiment, the RFT reinforcement 22includes a relatively solid member that can be perforated with openings46. The term “opening” and like terms are used broadly and include anyaperture formed in the support and/or reinforcement, such as holes,slots, and other apertures. The term “perforate” and like terms are usedbroadly and include any method for forming openings in a material, suchas molding, drilling, stamping, punching, melting, and other apertureforming methods.

[0066] Openings 46 allow the molding material to flow therethrough.Advantageously, the openings allow the molding material to flow throughand around the reinforcement 22, so that the reinforcement 22 is atleast partially encapsulated, and preferably substantially encapsulated,by the molding material. It is to be understood that the openings areoptional and other embodiments may not have substantial openings.

[0067] As an example, the RFT reinforcement can be made from arelatively thin tube of material and processed by punching, drilling,cutting or otherwise forming openings 46. The material can be metal,composites, fiber reinforced composites, plastics, or other materialthat can be shaped into an essentially circular form. The terms“circular” and “cylindrical” are used broadly and include any shapeforming a loop without hard corners, such as circles, ellipses andirregularly shaped geometric figures.

[0068]FIG. 5B is a partial schematic cross-sectional view of an opening46 formed in the RFT reinforcement shown in FIG. 5A. A surface 48 of theRFT reinforcement 22 has been perforated. In at least one embodiment,the surface 48 can be perforated, so that a tab 50 is disposed adjacentsurface 48 to form the opening 46. The tab 50 can be useful inincreasing a coupling force to subsequent molded material of the innerhoop 20 that surrounds the reinforcement, shown in FIGS. 1 and 2. Thetab can also be useful is locating the reinforcement in a mold. The tabcan extend in any direction, including toward the center of thereinforcement. In other embodiments, the opening 46 can be formedwithout producing a tab 50.

[0069] One property indicating suitable rigidity of the RFTreinforcement 22 is by measuring the deformation in a drop test. A testregimen for the reinforcements was to form a cylindrical reinforcementand determine the average diameter of the reinforcement from side toside when the reinforcement was lying horizontally in a state of rest.The reinforcement was rotated vertically, that is, the axis 23 that isshown in FIG. 4, was substantially perpendicular to gravity andelevated, so that a lower portion of reinforcement was at a height ofabout two meters above an uncushioned concrete floor. Other hardsurfaces could also be used, such as wood, metal, or relatively rigidpolymer surfaces. The reinforcement was dropped to test the amount ofdeformation occurring after the drop when the reinforcement was againlying horizontally in a state of rest.

[0070] Generally, the resulting shape was elliptical rather thancircular. The dimensions of the resulting ellipse were measured afterrecovery when the reinforcement was again horizontal in a state of rest.The resulting dimension from side to side of the reinforcement after thedrop generally decreased in a direction of the drop or increased in acorresponding amount in a direction perpendicular to the drop. Adifference between either the decreased amount in one direction or theincreased amount in the other direction compared to the original averagediameter was used to calculate an average deformation percentage. Thereinforcement was then reshaped into a circle prior to the next test.The test was repeated several times. Additionally, any delamination wasnoted as would cause the RFT reinforcement to be difficult to insertinto a mold.

[0071] It was found that if the deflection percentage was about 20% orless, then the reinforcement generally had a rigidity that allowed thereinforcement to be inserted relatively easily into the support mold.Naturally, the deflection percentage could be more and still be usable.An advantageous percentage was about 10% or less, a more advantageouspercentage was about 5% or less, and an even more advantageouspercentage was about 1% or less. Some examples of various reinforcementsthat were prepared, tested, and inserted into the support mold in orderto mold a support are described herein.

[0072] The reinforcement can be produced by several methods, some ofwhich are described below. Generally, the reinforcement can be producedindividually, or can be produced as from tubular members and individualreinforcements cut therefrom. As used herein, “cut” includes any type ofsevering of one piece from another. For example and without limitation,the cut could be performed by a cutter, such as a saw with one or moreabrasive wheels.

[0073]FIGS. 6-10 show at least five variations of forming thereinforcements. Some of the variations include, for example, filamentwinding around a mandrel, wrapping a material around a mandrel, moldinga reinforcement in a die, supplying longitudinal members in the windingof a reinforcement, and tangentially molding a reinforcement. Naturally,other methods are possible and the examples herein are non-limiting.

[0074]FIG. 6 is a schematic view of one system for producing a filamentwound RFT reinforcement 22 shown in FIGS. 1-5B by a filament windingmethod and system. The system 60 includes a support mandrel 62, one ormore reinforcement supplies 64, 66, and 68, such as drums or reels, aheater or other curing element(s) 76, and can include a cutter 80. Thesupport mandrel 62 provides a surface about which filaments from thereinforcement supplies can be wound.

[0075] In at least one embodiment, one or more reinforcement supplies64, 66 can be used to wind the filaments around the mandrel in atransverse direction at an angle to the center axis of the mandrel. Theangle depends upon the speed of the rotating mandrel coupled with thespeed at which the reinforcement supplies and/or material move along theaxis of the mandrel. The angle would generally be between about 0degrees and about 90 degrees and generally is between about 45 degreesand about 90 degrees. Further, an angle between intersecting filamentscan be varied. For example, the transverse members 42, 42 a shown inFIG. 4 can intersect at angles from greater than about 0 degrees to lessthan about 180 degrees.

[0076] In at least one embodiment, a reinforcement supply 68 can providea substantially circumferential band of filaments. The band of filamentsforms the one or more circumferential members 44, shown in FIG. 4.Generally, the circumferential member(s) 44 can be formed by winding thefilaments at a large winding angle, i.e., almost perpendicular angle tothe mandrel axis, to form a substantially continuous winding offilaments and spacings from multiple revolutions of the filaments aroundthe mandrel, although any angle between about 0 degrees and about 90degrees can be used. Thus, the circumferential member(s) 44 can be acontinuous band that progressively is wound along the mandrel in atleast one embodiment. Further, the circumferential member can be formedfrom one or more wraps, such as two, three, or more wraps to increase ahoop strength of the circumferential member. Alternatively, thefilaments can be wound in discrete sections and cut to form acircumferential member and then the reinforcement supply 68incrementally positioned to wind another circumferential member alongthe mandrel. Further, the filaments can be wound in multiple layersand/or widths to form a variety of thicknesses and widths ofcircumferential members and coupled to create the one effective layerdescribed herein. Still further, the filaments can be wound at differentrates of traverse, so that some filaments are wound closer together thanother filaments. An example is described in reference to FIG. 6a.

[0077] Thus, the RFT reinforcement can be formed as an assembly oftransverse and circumferential members. The geometry of the woundfilaments on the mandrel can leave openings for moldable material topass therethrough in molding the RFT support. Further, various lengthsof the RFT reinforcement can be made on the mandrel, including singleRFT reinforcements or multiple widths of RFT reinforcements that can becut into individual RFT reinforcements through processing.

[0078] It is to be understood that variations of the winding arecontemplated by the invention. For example, the various figures andmethods described herein can use one or more of the reinforcementsupplies, alone or in combination, to form various combinations of oneor more transverse and/or circumferential members. Further, severalreinforcement supplies are shown, but the number is not limiting and canvary depending on the various capabilities and production requirements.Also, the speeds and feeds of the various supplies can be varied asappropriate to produce desired thicknesses, spacings, shapes, and soforth, as would be apparent to those with ordinary skill in the art,given the understanding provided by the description of the inventioncontained herein.

[0079] In at least one embodiment, one reinforcement supply can be usedto produce the transverse members by traversing the mandrel in onedirection while winding and then traversing in another direction toproduce another transverse member at a different angle. Further, thesame reinforcement supply can be used to wind the transverse member ormembers and the circumferential members, for example by changing thetraverse or rotation speeds for the transverse members compared to thecircumferential members.

[0080] Such production capabilities in accordance with the teachings ofthe present invention and any associated software as could be performedby those with ordinary skill in the art, having been shown theunderlying purposes and intent of the present invention, can be includedwith a production machine. One commercially available filament windingsystem is available from Sidewinder Filament Winding Systems of LagunaBeach, Calif., USA.

[0081] Returning to FIG. 6, one or more of the reinforcement suppliescan pass through an applicator. For example, an applicator 70 is coupledto the reinforcement supply 64, an applicator 72 is coupled to thereinforcement supply 66, and applicator 74 is coupled to thereinforcement supply 68. The filaments pass through the applicators andbecome coated with material, such as a thermoplastic or a thermosetpolymer, and then are wound onto the mandrel. The coating material caninclude, for example and without limitation, an epoxy resin, including avinyl epoxy ester resin, monomer, monomer mixture, polyurethane,styrene, polyester resin, phenolic resin, polymer, or other thermosetresins, thermoplastic resins, or combinations thereof. The applicators70, 72 and 74 can include bath, spray, powder coating, extruders, andother forms of applying a material to a filament or cloth. An exemplaryline of polymer resins is a line of thermoset vinyl epoxy ester resinsknown as Derakane® resins that are manufactured by The Dow ChemicalCompany, such as Derakane® 411, 510N, Momentum, and other resinssuitable for coating a material and causing adherence to adjacentmaterials.

[0082] The coating materials, used in their appropriate curing system,are then allowed to cure to form a tubular member 78 through activemethods, such as induced activation, or passive methods, such asallowing the cure in ambient conditions. For example, in active methods,a thermoplastic may need to be crosslinked by passing the mandrelthrough the curing element 76, such as a heater or a source of actinicradiation. Other catalytic reactions can occur without the necessity ofheat or actinic radiation. Further, some resins can be cured withultraviolet radiation, X-rays, and other activation methods of a curablepolymer.

[0083] The tubular member 78 can be any length desired. For example, thetubular member can be formed a sufficient length to produce multiplesections and then cut into individual reinforcements. Alternatively, thetubular member can be formed to a sufficient length necessary for anindividual reinforcement. Either alternative can use any of the methodsdescribed herein.

[0084] The tubular member 78 can be brought to a cutting station of thesystem 60 which includes a cutter 80. The cutter 80 severs one or moreportions of the tubular member 78 to form a unitary, relatively rigidreinforcement 82. The tubular member can be cut on the mandrel or can beself-supporting and removed from the mandrel prior to cutting. Thereinforcement 82 can then be used in forming the RFT support 16 shown inFIGS. 1-3.

[0085] A variation in the method described relative to FIG. 6 includesproviding a thermoplastic film or other polymeric material on themandrel 62 prior to winding the filaments from the reinforcement supply64, 66, and 68. The filaments are wound onto the mandrel 62 withoutnecessitating passing the filaments through the applicators 70, 72 and74. Stated differently, the coating is applied to the filaments from thepolymeric material on the mandrel. The wound and coated filaments can becured as described above. Alternatively, the polymeric material can beprovided after the filament material is wound on the mandrel by a numberof methods, including applying a polymeric film over the filamentmaterial, spraying, dipping, or otherwise coating the material.

[0086] Another variation is to apply the polymeric material or othercoatings to the filaments prior to winding the filaments. Suchmaterials, known as pre-impregnated (“pre-preg”) materials, can bepartially cured and then subjected to final curing after assembly. Theresin can be cured by reaction, actinic curing, such as ultraviolet orX-ray curing, heat, or other curing methods.

[0087] In one embodiment, the applicators can use a pultrusion method toapply a coating to the material. As is known to those in the art, apultrusion method is essentially a continuous molding process.Reinforcing fibers, such as glass fibers, or other materials are pulledthrough an applicator such as a resin bath or thermoplastic extruder toapply a coating to the material. The material can then be used to formthe RFT reinforcement. In such embodiment, one or more of theapplicators 70, 72 and 74 could include the structure that pulls thematerial through the coating process.

[0088] Further, the process could be used to form a sheet of coatedfibers. The resulting sheet could be wound around a mandrel, sealed uponitself to produce a tubular member, and optionally perforated. One ormore RFT reinforcements can be cut from the tubular member.

[0089]FIG. 6a is a detailed schematic of one embodiment of transversemembers 42, 42 a and circumferential members 44, 44 a, 44 b andassociated winding. A reinforcement supply 68 can be moved along themandrel length to supply the reinforcement to the mandrel 62. Thespacing and number of the circumferential members can depend on thetotal length of the final RFT reinforcement, structural characteristics,including the width of the reinforcement, costs, and other factors and,thus, can vary from time to time and from product to product.

[0090] Further, the filaments can be wound at different rates oftraverse or rotational speeds, so that some filaments are wound closertogether than other filaments. Thus, transverse members 42, 42 a andcircumferential members 44, 44 a, 44 b could be formed from the samematerial during a winding process, but formed at different windingtraverses and/or speeds, so that the spacing is changed to produce thevarious members.

[0091] In at least one embodiment, one or more circumferential members44 a, 44 b can be disposed adjacent the final edges of the RFTreinforcement after cutting the RFT reinforcement to length. Such edgescan assist in placement, safety, and/or further processing. Thecircumferential members 44 a, 44 b can be formed at predeterminedintervals, where a cutter 80 can cut the layer of bonded traverse andcircumferential members into at least one RFT reinforcement 82, as alsoshown in FIG. 6. The members 44 a, 44 b can be formed with a relativelysmall gap or even no gap therebetween compared to gaps between adjacentcircumferential members 44. Thus, when an RFT reinforcement is cut fromthe tubular member 78 between the members 44 a, 44 b, the RFTreinforcement is formed with a circumferential member adjacent each cutedge. The circumferential members on the edge of the reinforcement canoffer improved edge smoothness.

[0092] One or more of the reinforcement supplies, such as supply 68, canwind the circumferential members 44 a, 44 b of reinforcement material onthe mandrel in conjunction with winding the members 42, 42 a by usingthe same material and changing the spacing between the various members.Alternatively, the members 44 a, 44 b can be formed as separate membersfrom members 42, 42 a.

[0093] In at least one embodiment, the circumferential members 44 a, 44b can be formed from a single circumferential member with or without asmall gap between the majority of the windings. If the members areformed together, then the combined width of the members can beincrementally wider than a circumferential member 44, such as twice thewidth. The cutter 80 can cut the combined circumferential member toproduce an RFT reinforcement that has a circumferential member adjacentthe cut edge(s) that can correspond in width to the circumferentialmember 44. The above embodiments are merely exemplary and the width,quantity, and placement of the circumferential members 44 a, 44 b canvary relative to the circumferential member 44.

[0094]FIG. 7 is a schematic view of another embodiment of a system forproducing an RFT reinforcement by wrapping reinforcement material arounda mandrel. A reinforcement supply 64 provides reinforcement material,such as one or more filaments, cloths, or other material, to a mandrel62. The reinforcement material is wrapped one or more times about themandrel and can be cut by cutter 88. A polymer supply 90 provides apolymeric material in a form of, for example, a thermoplastic film, amolten web, an adhesive tape, or other suitable media for application toreinforcement material. The polymeric material can be wound around themandrel with the reinforcement filament from the reinforcement supply64. The polymeric material can be cut by cutter 92 to an appropriatelength. The reinforcement filament and polymer can be pressed togetherby a roller 94 placed against the mandrel 62. The materials form atubular member 78 which can be cured and if necessary cut to anappropriate length to form a RFT reinforcement, as described in FIG. 6.The order of the materials can be reversed, so that the filament iswrapped after the polymer. Thus, the materials that are wrapped on themandrel can be wrapped directly or indirectly on the mandrel herein.Further, the polymer supply 90 can provide a fluid, such as in a spray,and apply the fluid to the mandrel and/or reinforcement.

[0095] A prefabricated scrim material having apertures formed thereincan be used for the RFT reinforcement material. The material can bewrapped more than once around the mandrel and, thus, the apertures onthe scrim material might not align with the underlying apertures of theprevious layer. The misalignment can cause unintended restricted flow ofmaterial through the reinforcement, so that the structural integrity ofthe molded RFT support can be affected. Therefore, a mandrel can be usedwith indexed “teeth” to align fibers, woven material, or other materialbeing wound or otherwise placed on the mandrel. Alternatively,sufficiently large apertures can be used, so that the apertures will notbecome unduly restricted through the various layers.

[0096] Alternatively, the material can be treated with a pressuresensitive adhesive around a mandrel, causing the material to be coupledto itself. In this method, at least one complete wrapping of material isused to allow some surface area by which the material can adhere toitself to form a tubular member and ultimately the RFT reinforcement.

[0097]FIG. 8 is a schematic view of another embodiment of the system formolding an RFT reinforcement. The system 60 includes a support mandrel62 and one or more reinforcement supplies 64, 66. The reinforcementsupply provides reinforcement material, such as filaments or cloth, towind around the mandrel 62 to produce a wound portion 96. The woundportion 96 is supplied to a profile extrusion die 98 having an innerand/or outer die. An extruder 100, for example, a thermoplasticextruder, is coupled to the profile extrusion die 98 for providingmolding material as a coating thereto. A blowing agent supply 102 canalso be coupled to the profile extrusion die 98. The profile extrusiondie provides the moldable material to the wound portion 96 in acontrolled shape and produces a tubular member 104. The tubular member104 can be conveyed through a cooler 106 that can also include supportfor the molded RFT reinforcement in the cooling process. If desired, thetubular member 104 can pass through a perforator 108 to provideperforations for the tubular member 104, so that moldable material usedto manufacture the RFT support 16 shown in FIG. 1 can flow therethrough.The tubular member 104 can progress to a cutting station having a cutter110 to cut a portion of the tubular member into one or more RFTreinforcements 112. The cut piece can be further shaped via compressionor thermal shaping if necessary. The order of the profile extrusion die,cutter, cooler, and perforator can be varied to produce the RFTreinforcement.

[0098] A variation of the above method can include forming a combinationof extruded or prefabricated thermal plastic films with reinforcingfabric in a relatively flat orientation. The film and fabric can bewound by being rolled into a tube using shaping equipment (not shown).

[0099]FIG. 9 is a schematic view of another embodiment of the system 60for producing a reinforcement 82 having longitudinal members. The systemis similar to the system described in FIG. 6. The system includes amandrel 62 about which is formed a matrix of wound filaments. One ormore reinforcement supplies 64, 66 provide one or more transversemembers of filament material around the mandrel 62. Further, one or morereinforcement supplies 130, 132, 134, and 136 provide one or morelongitudinal members. Although various numbers of reinforcement suppliesare shown, the number can vary from one to any number as appropriate inthis and any other embodiment disclosed herein.

[0100] The mandrel 62 can include a film, a molten web, or adhesive tapeto maintain the location of the filaments prior to curing. In at leastone embodiment, the mandrel does not rotate relative to thereinforcement supplies 130, 132, 134 and 136 while the longitudinalmembers are placed. In other embodiments, one or more of thereinforcement supplies can rotate about the mandrel. Still further, inother embodiments, both the mandrel and the reinforcement supply orsupplies can both rotate.

[0101] The reinforcement supplies 64 and 66 provide filament material tothe mandrel as the mandrel and/or the reinforcement supplies 64, 66 arerotated relative to the mandrel. The longitudinal members can include afusible polymer to hold transverse members in position. Alternatively,an applicator 138 is provided to spray, flow, or otherwise apply amaterial to the wound portion 140. The wound portion is allowed to cure.For example, if a thermoplastic is used, the wound portion 140 can beplaced in a curing element 76 to melt, fuse, or crosslink thethermoplastic. The resulting tubular member 142 can be removed from themandrel and cut into the discrete sections to form the RFT reinforcement82.

[0102]FIG. 10 is a schematic view of another embodiment of a system forproducing an RFT reinforcement using a tangential molding process.Generally, the tangential molding process can use a thermoplastic orother polymeric material that is injected into a mold. One or moreportions of the mold can rotate so that the injected material is forcedaround the mold's perimeter. The rotation causes the polymer to flowaround the mold to align entrained filaments along a circumference ofthe mold. The molded part can be allowed to cool and solidify and theRFT reinforcement removed from the mold with the filaments inappropriate alignment. Openings in the molded part can be formed toallow molding material for the RFT support to flow therethrough in thesubsequent support molding process.

[0103] A mold 116 can include one or more sides 118, a bottom 120, and atop 124. A support 122 can support one or more portions of the mold 116.A shaft 126 can be inserted through the top 124. One or more seals, suchas seals 115, 117, 119, and 121, can be disposed at various interfacesbetween the shaft 126, top 124, sides 118, and bottom 120. The seal(s)can include a bearing. One or more motors 123, 125 can be used to rotateand/or translate portions of the mold. The motors can be coupled to acontroller 127 for control thereof. An injection point 129 coupled toone or more portions of the mold 116 can be used to introduce themolding material into the mold.

[0104] In operation, the molding material is introduced into the moldand the shaft can be rotated. The fluid properties of the moldingmaterial in conjunction with the rotating shaft cause the moldingmaterial to accumulate adjacent the sides 118. Filaments entrained inthe molding material can also become aligned around the circumference ofthe sides 118. The molded part is allowed to solidify and removed fromthe mold. For example, the bottom 120 can be separated from the top 124and the molded part removed from the mold.

[0105] Variations are possible. For example and without limitation, theshaft 126 can be stationary and one or more other portions of the mold116, such as the sides 118, can rotate around the shaft. Further, theshaft and the one or more other portions of the mold can rotate togetheror in opposite directions. The shaft 126 can be inserted through thebottom 120, the sides can be coupled to the top 124, the ports can be inone or more alternative positions such as 129 a, 129 b, 129 c orcombinations thereof. Multiple injection points can be used. The anglesof the injection points can also vary. For example, one or moreinjection points can be angled along the side of the mold to assist inprealigning the material, as it is introduced into the mold. Injectionis used broadly and includes herein any known method of introducing amolding material into a mold. Other equipment (not shown), such asheaters, coolers, and electrical controls could vary the production ofthe reinforcements. The schematic is used to illustrate a tangentialmolding method and is not limiting of the underlying method of atangential molding method, as many variations are possible.

[0106] It is to be understood that a similar result can include using atangentially directed port(s) with or without the mold or shaftrotating. For example, a thermoplastic can be injected into the mold ina direction that forces the polymer to flow around a reinforcement hoopto circumferentially align entrained filaments. As the mold is filledwith material, the filaments can flow around the circumference of themold. The molded part can then allowed to solidify and the RFTreinforcement removed from the mold with the fibers in position. For thepurposes of this disclosure, tangential molding is meant to include suchvariations.

[0107] Colored Indicator for RFT Support

[0108] As described herein, the RFT supports can vary by manufacturer,size, style, and other attributes. Shipping, installation, repair, andother post-manufacturing uses can benefit from some visual indicator ofone or more of the attributes of the RFT support to avoid confusion withother RFT supports. The present invention provides a heretofore unknownand unused colored indicator(s) to indicate one or more attributes ofthe RFT support.

[0109]FIG. 11 is an exemplary RFT support 16 having an axis 17, an outerperiphery 141, an inner periphery 143, side walls 144, and a preselectedcolored indicator 139. In some embodiments, the colored indicator can beapplied to the RFT support on one or more surfaces of the support. In atleast one embodiment, the colored indicator can be incorporated intomaterials used to form the RFT support. For example, the coloredindicator can be formed into the RFT support during a molding process ofthe RFT support. The colored indicator could be mixed with the RFTsupport components to produce a colored RFT support.

[0110] Where the RFT support is a polyurethane, it can be formed, forexample and without limitation, by a reaction injection molding (RIM)process. This process is well established in the art and consists offilling a closed mold with highly reactive liquid starting componentswithin a very short time, generally by using a high output, highpressure dosing apparatus after the components have been mixed. In oneembodiment, the reaction injection molding process consists of the useof at least two liquid streams (A) and (B) which are impingement mixedunder moisture free conditions. Stream A contains the organicpolyisocyanate, typically a liquid polyisocyanate. Stream B contains theisocyanate-reactive component which typically is a polyol and/or anamine polyether, and usually a chain extender containing amino and/orhydroxyl groups. The mixture is then allowed to cure within the mold torender the finished product. The colorant can be added to either the “A”component or the “B” component. Alternatively, the colorant could beadded to both the “A” component and the “B” component.

[0111] The coloring can be visually apparent on one or more surfaces ofthe RFT support. Further, the coloring could be substantially uniformacross one or more surfaces of the RFT support, especially if thecoloring is substantially uniformly mixed with the components. Thecoloring indicator can be a stable or inert material, such as a dye, orcan be a reactive ingredient that can be activated chemically,electrically, photochemically, thermally, or by any other method ofcausing an ingredient to react. Further, the reactive ingredient canreact with components used in the molding process of the RFT support toproduce one or more colors.

[0112]FIGS. 12a-12 f are exemplary RFT supports having variations ofcolored indicators. The colored indicator can be formed, appliedthereto, or otherwise coupled with the RFT support in addition to or inlieu of the colored indicator being incorporated into the RFT support asdescribed above. The colored indicator can be coupled to one or moresurfaces of the RFT support. In some embodiments, the RFT support can besubstantially covered with the colored indicator. A substantial coveragecan also form a barrier for gaseous or liquid fluids or other substancesaffecting the RFT support. In some embodiments, the colored indicatorcan include a single representation or a plurality of representations ofmarkings, symbols, or other visually apparent indicia to indicate theone or more attributes of the RFT support.

[0113] The colored indicator can be a uniform color that is coupled toone or more surfaces of the RFT support. Alternatively, the coloredindicator can include variations in colors. For example, a singleindicator can be used with different colors indicating differentattributes, such as manufacturer, size, or other attributes. Morecomplicated schemes can be used with, for example, multiple coloredindicators having multiple colors that can be used to indicate one ormore attributes.

[0114] The colored indicator can also indicate attributes of use,condition, wear, and other operation-related attributes. For example, acolored indicator can be applied to the RFT support and then changecolors when one or more operation attributes occur, such as an operatingcondition(s) or an event(s), that would cause a response from thecolored indicator. In at least one embodiment, a colored indicator canchange colors when a mounted tire deflates and rolls against the RFTsupport during use. The wear could cause increased heat, friction, orother phenomena and cause the colored indicator to temporarily orpermanently signal a change. Similarly, colored indicators can be usedto indicate operating wear, unusually high stress, and other operatingconditions.

[0115] Further, a colored indicator can be used to indicate one or moredegrees of operating conditions, such as and without limitation, a timebased or stress based intermittent use, average use, and intensive use.Such indications can be based, for example, on the amount of heat orother operating conditions produced during one or more uses. Further,multiple colored indicators can be used that react to varying degrees ofattributes to indicate a range of conditions. Similarly, multiplecolored indicators can be used to indicate multiple operation-relatedattributes. Examples of commercially available signaling paints that canbe used for this invention include Temp-Alarm by Tempil, Inc. of SouthPlainfield, N.J., USA and Thermo-Paint by Samkwang Corp. of Buchon-City,Kyonggi-Do, Korea.

[0116] The colored indicators 150 a-f can be formed, affixed, placed, orotherwise coupled to the RFT support on one or more surfaces of thesupport. For example, the colored indicators can be coupled to the outerperiphery 141, to the inner periphery 143, to side walls 144, or acombination thereof.

[0117] Still further, the style, number, shape, position and angle withrespect to the axis 17 and other datums, depth, width, and/or placementof the colored indicator on the RFT support can vary and the examplesshown are not intended to be limiting but merely representative of someof the possible variations. Other variations can and would exist. Thevariations can include the above list and other variations, such asdashes, stripes, geometric patterns, and so forth.

[0118] The colored indicators can be applied after the molding of theRFT support in any conventional method. For example and withoutlimitation, the colored indicator can be applied by gravure processes,rolling, spinning, flowing, brushing, electrostatic deposition, dipping,spraying, immersing, powder coating, or other coating/painting methods.Optionally, the colored indicator can be cured on or with the RFTsupport. The colored indicator can also be applied in the RFT supportmold prior to molding, during molding, or after molding.

[0119] One exemplary method of using the RFT support having a coloredindicator includes the ability to readily select a wheel rim and match aRFT support suitable to that wheel rim based on the colored indicator.Naturally, the tire can be matched with the appropriate rim and/orsupport, as well.

[0120] The following example is non-limiting and is intended as merelyrepresentative possibilities of aspects of the invention disclosedherein.

EXAMPLE 1 Production of an RFT Support

[0121] The following is one example of the production of an RFT support.Naturally, other procedures are available and the example is intended toinclude only one of many possibilities. A pre-fabricated RFTreinforcement was inserted into the inner radius of an RFT support moldprior to closing the mold. The RFT reinforcement can be held in positionin the mold by pins or other locating devices. The locating devices canbe coupled to the mold or to the RFT reinforcement. In at least oneembodiment, the locating devices can be an integral part of the RFTreinforcement, as when tabs or other elements extend from the RFTreinforcement.

[0122] An RFT support was reaction injected molded (RIM) into this mold,using a polyurethane-forming, two component, reaction injection moldingformulation based on methylene diphenyl isocyanate (MDI), polyetherpolyols, diamine chain extender, a catalyst and a surfactant. The polyolformulation and the isocyanate prepolymer were metered into animpingement mixhead using a metering machine. The reacting liquid passedfrom the mixhead into a centered, bottom, axially-oriented sprue. Theliquid was then directed from the sprue into multiple spoke runners inthis example. The spoke runners fed a circumferential runner, located ona lower inner diameter relative to the RFT support being molded. Thecircumferential runner allowed the reacting polymer to flow over a filmgate into a lower portion of the RFT support being molded. The RFTsupport mold cavity was oriented substantially horizontally, that is,with the axis approximately parallel to gravity during the mold fill.The top of the mold included release vents for the expulsion of air. Thereacting polymer filled the mold from bottom to top. The mold was heldat a temperature of about 70° C. during introduction of the reactingpolyurethane. The mixhead was closed upon filling the mold, and thepolymer was allowed to cure for 45 seconds. The mold clamp was openedand the RFT support removed. At least a portion of the RFT support waspainted with a colored paint and indicated at least one attribute of theRFT support.

[0123] While the foregoing is directed to various embodiments of thepresent invention, other and further embodiments can be devised withoutdeparting from the basic scope thereof. For example, the various methodsand embodiments of the invention can be included in combination witheach other to produce variations of the disclosed methods andembodiments. Discussion of singular elements can include plural elementsand vice-versa. Also, any directions shown or described such as “top,”“bottom,” “left,” “right,” “upper,” “lower,” and other directions andorientations are described herein for clarity in reference to thefigures and are not to be limiting of the actual device or system or useof the device or system. The device or system can be used in a number ofdirections and orientations. Further, the order of steps can occur in avariety of sequences unless otherwise specifically limited. The varioussteps described herein can be combined with other steps, interlineatedwith the stated steps, and/or split into multiple steps. Additionally,the headings herein are for the convenience of the reader and are notintended to limit the scope of the invention.

[0124] Further, any references mentioned in the application for thispatent as well as all references listed in the information disclosureoriginally filed with the application are hereby incorporated byreference in their entirety to the extent such may be deemed essentialto support the enabling of the invention(s). However, to the extentstatements might be considered inconsistent with the patenting of theinvention(s), such statements are expressly not meant to be consideredas made by the Applicants.

What is claimed is:
 1. A run flat tire (RFT) support, comprising: a) amolded portion having an outer circumference and an inner circumferenceand adapted to mount to a wheel rim to support a deflated tire when thetire is rolling on a surface, the molded portion further comprising acolored indicator that indicates at least one attribute of the RFTsupport; and b) at least one RFT reinforcement molded into the moldedportion.
 2. The RFT support of claim 1, wherein the colored indicator isadapted to indicate at least one operation attribute of the RFT support.3. The RFT support of claim 1, wherein the RFT reinforcement comprisesone effective layer and has a rigidity sufficient to deform about 20% orless when dropped from about two meters high to a hard surface when anaxis of the reinforcement is substantially perpendicular to gravity. 4.The RFT support of claim 1, wherein the colored indicator is applied tothe molded portion after molding.
 5. The RFT support of claim 1, whereinthe colored indicator is applied by gravure, roll, spin, flow, brush,electrostatic, dip, spray, immersion, powder coat, coat, paint, or somecombination thereof.
 6. The RFT support of claim 1, wherein the coloredindicator is formed in the molded portion by a colorant added in amolding process of the molded portion.
 7. The RFT support of claim 6,wherein the colored indicator can be added to either an A-side or aB-side or a combination thereof in a reaction injection molding (RIM)process.
 8. The RFT support of claim 6, wherein the colored indicator isformed in the molding process by a reaction of components.
 9. The RFTsupport of claim 6, wherein the colored indicator is a dye.
 10. The RFTsupport of claim 1, wherein the colored indicator is substantiallyuniform across at least one surface of the molded portion.
 11. The RFTsupport of claim 1, wherein the colored indicator is formed from one ormore indicia and are perpendicular, parallel, or at one or more anglesto a central axis of the molded portion.
 12. The RFT support of claim 1,further comprising a wheel rim wherein the colored RFT support isadapted to be mounted to the rim.
 13. A run flat tire (RFT) support,comprising a molded portion having an outer circumference and an innercircumference and adapted to mount to a wheel rim to support a deflatedtire when the tire is rolling on a surface, the molded portion having acolored indicator that indicates at least one attribute of the RFTsupport.
 14. The RFT support of claim 13, wherein the colored indicatoris applied to the molded portion after molding.
 15. The RFT support ofclaim 13, wherein the colored indicator is formed in the molded portionby a colorant added in a molding process of the molded portion.
 16. TheRFT support of claim 15, wherein the colored indicator is formed byadding to either an A-side or a B-side or a combination thereof in areaction injection molding (RIM) process.
 17. The RFT support of claim13, wherein the colored indicator is substantially uniform across atleast one surface of the molded portion.
 18. The RFT support of claim13, wherein the colored indicator is formed from one or more indicia andare perpendicular, parallel or at one or more angles to a central axisof the molded portion.